Charcoal flap assembly for gas grills

ABSTRACT

The present invention is drawn to a gas grill or add-on component for a gas grill that provides the additional functionality of permitting grilling with either gas, charcoal briquettes, or wood chips. The additional functionality of being able to cook with charcoal or wood chips on a gas grill is achieved by positioning moveable flaps in a second position thus providing a horizontal surface above the gas burner, yet below the cooking surface, upon which to place charcoal briquettes. Spaces on either side of each pair of flaps allow the gas burners to be used to ignite the charcoal briquettes or wood chips. Once the charcoal briquettes or wood chips are ignited, use of the gas burner is discontinued. The charcoal or wood chips are permitted to burn to complete ash, then the moveable flaps are placed to a first position thus forming an apex that permits the ash to fall into an ash pan located in the bottom of the firebox. Alternatively, if cooking with gas is preferred, the movable pairs of flaps can be positioned in the first position thus forming an apex arrangement over the gas burners to protect the burners from drippings.

RELATED APPLICATION

[0001] This application claims priority from provisional application No. 60/367,149 filed on Mar. 22, 2002.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention pertains to an outdoor grill for cooking food that is heated with a gas burner, traditional charcoal, wood chips, or a combination thereof. More specifically, a grill that has an adjustable platform for using charcoal briquettes or wood chips as a heating source where the charcoal briquettes or wood chips can be arranged on the adjustable platform above the gas burner, the gas burner can then be ignited which in turn will ignite the charcoal briquettes or wood chips. If charcoal or wood chips are not desired, the adjustable platform can also be positioned to permit heat transfer from the gas burner to the food being cooked. The platform also provides protection for the gas burners from grease and other flammable substances by channeling them away from the direct flame of the gas burner.

[0004] 2. Background Description

[0005] Prior art grills are either fueled with a gas burner or with charcoal, but generally not both in a single combination.

[0006] U.S. Pat. No. 6,314,868 to Christensen et al. discloses a barbeque grill that cooks food by providing direct or indirect heat from a heat source of the cooker to the food. The outdoor cooker has a gas or charcoal heat source that provides direct and indirect heat to foods supported on a cooking surface of the grill by operation of a plurality of parallel louvers between the heat source and grill that are moved between first, upright positions of the louvers that provide direct heating of the food and second, angled relative positions of the louvers that provide indirect heating of the food.

[0007] U.S. Pat. No. 6,260,478 to Harniet discloses a heat dissipation system that uses a pair of panels rotatably mounted in a grill, which allows a cook to equalize the heat radiated within a gas or electric grill to provide more even heat distribution and prevents wind from extinguishing the burner flame, even in the presence of a crosswind. A grease drainage system is also described for a gas or electric grill.

[0008] U.S. Pat. No. 5,890,422 to Clark et al. discloses a convertible drip pan that can be opened and closed between the food supporting rack and the cooking heat source. Rapid preheating can be accomplished as well as searing of desired food products, followed by closing of the drip pan to prevent unwanted flare-ups caused by juices dripping from the food being cooked. This closing of the drip pan allows the food to cook slower than over direct heat. Different types of heat sources can be used in conjunction with Clark et al. such that the problem of the bottom of the housing rusting out in the area adjacent the round burner below the heat deflecting plate is reduced.

[0009] U.S. Pat. No. 2,985,097 discloses a gas broiler with a movable louvers or dampers interposed between the gas burners and the grates so that heat reaching the grates from the burners can be readily controlled.

[0010] What would be truly useful is a gas grill or add-on component for a gas grill that includes means to protect burners from drippings when used as a gas grill, but that has additional utility by adjusting to provide a platform for using charcoal as a heat source and wherein the gas burners can be used to light the charcoal. Additionally, a means to provide for ash removal would also be desirable.

SUMMARY OF THE INVENTION

[0011] The present invention is drawn to a gas grill or add-on component for a gas grill that provides the additional functionality of permitting grilling with either gas, charcoal briquettes, or wood chips by positioning moveable flaps in a first position thus providing a horizontal surface above the gas burner, yet below the cooking surface, upon which to place charcoal briquettes or wood chips. The flaps may also be arranged individually or to function as flap pairs as in the preferred embodiment. The flap pairs can be arranged to provide channels on each side of the flap pairs by gapping the flap pairs. Channels on either side of each pair of flaps allow the gas burners to be used to ignite the charcoal briquettes. Once the charcoal briquettes or wood chips are ignited, use of the gas burner is discontinued. After cooking the charcoal or wood chips is permitted to burn to complete ash, then the moveable flaps are moved to a second position thus forming an apex that permits the ash to fall into an ash pan located in the bottom of the firebox.

[0012] If cooking with gas is preferred, the movable pairs of flaps can be positioned in a second position thus forming an inverted “V” like apex arrangement over the gas burners to protect the burners from drippings when used as a gas grill. When the drippings are channeled away from the gas burners they are vaporized thus creating a pleasurable outdoor grilling aroma and smoke.

[0013] It is therefore an object of the invention to provide a method and apparatus to allow charcoal grilling in a gas grill.

[0014] It is another object of the invention to provide a method and apparatus to allow charcoal to be lit using a gas burner from a gas grill.

[0015] It is yet another object of the invention to provide a method and apparatus to protect gas grill burners from drippings and ashes.

[0016] It is yet another object of the invention to diffuse the heat through means by flap control.

[0017] It is a further object of the invention to provide a method and apparatus to provide easy removal of charcoal ashes from a gas grill.

[0018] It is another object of the invention to provide a method and apparatus to allow simple conversion or retro fitting of a standard gas grill to accommodate a mode for charcoal grilling.

[0019] These and other objects and advantages of the present invention will become apparent from a study of the following description and the accompanying drawings which are merely illustrative of such invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020]FIG. 1 illustrates the present invention in a configuration for use in gas grilling with the flaps up to form an apex configuration.

[0021]FIG. 2 illustrates a close-up view of the configuration for use in gas grilling with the flaps up to form an apex configuration.

[0022]FIG. 3 illustrates the present invention configured for use in charcoal grilling with the flaps down to form a horizontal support.

[0023]FIG. 4 illustrates a configuration for use in charcoal grilling with the flaps down to form a horizontal support for the charcoal.

[0024]FIG. 5 illustrates a close-up view of the configuration for use in charcoal grilling with the flaps down to form a horizontal support.

[0025]FIG. 6 illustrates a bar used in the present invention for varying the position of the pairs of flaps.

[0026] FIGS. 7A-7B illustrate cross-sectional views of the flaps in the apex and flat positions over the burners.

[0027] FIGS. 8A-8G illustrates various views of the flaps used in the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

[0028] As shown in FIG. 1, the present invention has a standard configuration for use in gas grilling, wherein the flap pairs 20 are positioned by a control bar 35 to form an inverted “V” like apex above the gas burner 12. Heat sources other than gas burners 12 can also be used such as electric heating elements. The flaps 25 can be arranged individually or to function as flap pairs 20 as in the preferred embodiment. The flap pairs 20 may be arranged to provide channels 40 on each side of the flap pairs 20 by arranging the flap pairs 20 so that a gap exists on either side of the flap pairs 20. When the flaps 25 of the flap pairs 20 are in this apex position they form an 20° to 60° angle to the horizontal and form a 40° to 120° inclusion angle. Different width flaps 25 can be used that will alter to location of the apex by altering to point of contact between the flaps 25 without departing to the scope of the invention. In this particular embodiment, three sets of charcoal flap pairs 20 are used to cover the three gas burners 12. In this position, the flaps 25 protect the gas burners 12 from dripping juices and fat by directing the dripping material away from the gas burners 12 to avoid flare-ups (i.e., by channeling grease away from the flame), but still imparts a grilled flavor to foods. An additional single end flap 15 is located at each side to provide full coverage across the firebox 10 area. Although it is possible to use fixed panels for this purpose, a preferred embodiment uses movable end flaps 15. Additionally, the flaps 25 can act as radiant panels to evenly distribute heat.

[0029] Any number of flaps 25 can be used. The total number of flaps 25 in the preferred embodiment however is proportional to the number of gas burners 12 and therefore can be calculated by the equation:

Total Number of Flaps=(Number of Gas Burners)(2)+2

[0030] As mentioned above, a channel 40 may be provided adjacent to each flap pair 20. These channels 40 remain regardless of the flap 25 position due to pivoting the flaps 25 at a point adjacent the channel 40 and allowing the flap pairs 20 to overlap at the apex. The flaps 25 are formed of any suitable metal and are preferably porcelain coated. Other suitable materials include steel, stainless steel and aluminized steel. If needed, slits 30 (not shown) for venting of gasses can be punched in each flap 25. The slits 30 can also aid ignition of the charcoal briquettes by allowing flames or hot gasses to pass through the flap 25 directly onto the charcoal briquettes. Decorative patterns or embossing can also be added to the flaps 25 without departing from the scope of the invention.

[0031]FIG. 2 illustrates a close-up view of the configuration for use in gas grilling with the flap pairs 20 and end flaps 15 up to form an apex configuration. As seen more clearly in this figure, overlap of the two flaps 25 that comprise the flap pair 20 at point “A” allows the flap pair 20 to form an actuate angle that prevents grease from falling on the gas burner 12. Grease from cooking is safely channeled away from the flames and gas burner 12 without ignition.

[0032] Upon movement of the control bar 35, the ramps 50 on the control bar 35 (additionally illustrated in FIG. 6) act on tabs 45 on the ends of the flaps 25 of the overlapping flap pairs 20 to rotate both flaps 25 about their pivots adjacent the channels 40 to position the flaps 25 in apexes, as additionally illustrated in FIG. 7A. In the preferred embodiment, the pivots are located off center on both of the ends of the flaps 25 where the back end joins the flaps' 25 longitudinal edge. The firebox 10 is adapted to receive the flaps' 25 pivot rod 60 which may be freely inserted or are held in place by inserting a cotter pin through the pivot rod 60 that extends outside of the firebox 10.

[0033] When the control bar 35 is moved such that the ramps 50 no longer contact the tabs 45, the flaps 25 rotate to a substantially horizontal position ranging from 0° to 10° from the horizontal, as illustrated in FIGS. 3, 4, 5, and 7B. These figures illustrate the present invention configured for use in charcoal grilling with the flaps 25 down to form a horizontal support for the charcoal. Typically, the control bar 35 will extend through the firebox 10 and include a heat resistant and insulating knob or lever positioned on its end to allow actuation by pulling. However, other actuating mechanisms may also be used. Other types of control bar 35 mechanisms can be used to actuate the flaps 25 including screw type devices and geared mechanisms.

[0034] The second position which is essentially horizontal places the flaps 25 close to the gas burners 12, the charcoal or wood chips can be quickly lit using the gas burners 12, but the flap 25 position is not suited to efficient combustion and therefore this lowered flap 25 position should only be used in conjunction with charcoal grilling.

[0035]FIG. 4 illustrates charcoal positioned on the horizontal flaps 25 in preparation for use. Note that the channels 40 are dimensioned such that typical charcoal briquettes will not pass therethrough. With the charcoal placed on the horizontal flaps 25, the gas burners 12 are ignited and operated for no more than 5 to 10 minutes so as to ignite the charcoal without the use of lighter fluids, paper, or the like. After the gas is turned off, the charcoal continues to burn until ready for cooking. It is then spread out and used in the usual manner for cooking. Alternatively, the charcoal may be randomly spread out on the horizontal flaps 25, the gas burner 12 ignited and operated for no more than 5 to 10 minutes so as to ignite the charcoal briquettes without the use of lighter fluids, paper, or the like. The gas is then turned off, just as before, and the charcoal continues to burn until ready for cooking.

[0036] The charcoal will eventually burn completely to ash. The flaps 25 are then raised using the control bar 35 thereby dumping the ashes through the channels 40 into the bottom portion of the firebox 10 for disposal while keeping the ash off the gas burners 12. Ash has the potential to block the ports on the gas burners 12, therefore it is important to channel the ash away from the gas burners 12 when dumping. The bottom of the firebox 10 can optionally be modified to expedite ash removal by any known means and/or can use the same means used for handling the grease.

[0037] FIGS. 8A-8G illustrate various views of the preferred flaps 25 used in the present invention. FIG. 8A shows a cross sectional view of the flaps 25 in position in the firebox 10 of a gas grill. In this embodiment, each flap 25, as shown in FIGS. 8A-8G, includes a pivoting rod 60 that is rotationally supported within the firebox 10. The flaps 25 included in the flap pairs 20 are illustrated in FIGS. 8E-8G and include an arched tab 45 at one end for engaging the control bar 35 and a similar arched tab 45A on the other end which may be used for engaging a support bar 55 when the flaps 25 are in a horizontal position and supporting the weight of the charcoal. The single, end flap 15 is illustrated in FIGS. 8B-8D and also includes an arched tabs 45, 45A to allow the side opposite the pivot rod 60 to be supported.

[0038] In use, the present invention can be incorporated and fabricated integrally with a gas grill design or it can be designed as a stand-alone, removable or convertible unit for aftermarket or add-on applications.

[0039] Fireboxes 10 are typically either spherically rounded or rectangular in shape, although other embodiments are possible. Though not shown, a cover having a complementary configuration to the firebox 10 is removably positioned on top of the firebox 10 for covering the cooking surface. The cover may be either completely removable or hinged to the back sidewall of the firebox 10.

[0040] Although described herein with respect to a particular embodiment, the invention can be practiced in numerous other embodiments without departing from the scope of the invention. For example, although disclosed in a gas grill with three side-by-side gas burners 12 running front-to-back, it is clear that the present invention could also be used in arrangements having a different number of burners 12, a different orientation of burners 12 (i.e. side-to-side), or a different type of heating element (i.e. radiant burner, electric element, etc.). Additionally, different flap actuation means can also be used, such as a rotating bar or separate actuators for each flap pair or flap. Different flap spacing and pivot points can also be used without departing from the scope of the invention. For example, the pivot in the preferred embodiment is located in the corner of the flap, but it can just as easily be located along the center of the flap or any other suitable location. Additionally, different flap configurations and numbers of flaps can be used, such as a configuration with no channels or even a single flap. 

What is claimed by Letters Patent is:
 1. A grill for cooking food comprising: a firebox with a bottom wall and at least one side wall that extends up from the bottom wall; at least one heat source, said heat source is located inside the firebox on the bottom wall; and at least one flap having a first and second longitudinal edge on opposite sides of a first and second width ends, the first width end is removable attached to a control arm, the control arm is located above the heat source and below a cooking surface.
 2. The grill of claim 1 wherein: a plurality of flaps each having a first and second longitudinal edge on opposite sides of a first and second width ends, the first width end is removable attached to the control arm, wherein the plurality of flaps are arranged as flap pairs.
 3. The grill of claim 1 wherein: the control bar adjusts the pitch of the flap with a plurality of ramps on the control bar from a first position where the flap is elevated between 20 to 60 degrees from the horizontal to a second position essentially horizontal.
 4. The grill of claim 2 wherein: the control bar adjusts the pitch of the flap pairs with a plurality of ramps on the control bar from a first position where the flap pairs are elevated between 20 to 60 degrees from the horizontal to form an apex to a second position essentially horizontal.
 5. The grill of claim 1 wherein: the heat source is gas fueled.
 6. The grill of claim 1 wherein: the bottom wall consists of a removable ash pan for catching grease and charcoal ash channeled by the flap away from the heat source.
 7. The grill of claim 1 wherein: the flap has an arched tab on the first width end for engaging the control bar.
 8. The grill of claim 1 wherein: the flap is vented for letting gasses through.
 9. The grill of claim 1 further comprising: at least one end flap having a first and second longitudinal edges on opposite sides of a first and second width ends, the first and second width ends are attached to the control arm.
 10. The grill of claim 2 further comprising: at least a first flap pair and a second flap pair, where each of the individual flaps comprising the flap pair has a first and second longitudinal edges on opposite sides of a first and second width ends, the first width end is attached to the control arm, the control arm is located above the heat source and below the cooking surface and a channel exists between the first flap pair and the second flap when the control arm is in the first position and the second position.
 11. A grill according to claim 1 wherein: the firebox has a bottom wall, a front wall and a back wall that are essentially parallel to each other and extend upward from the bottom wall, and a left side wall and a right side wall that extend upward from the bottom wall and are connected to the front wall and the back wall, and are essentially parallel to each other.
 12. A grill for cooking food comprising: a firebox with a bottom wall and at least one side wall that extends up from the bottom wall; at least one heat source, said heat source is located inside the firebox on the bottom wall; and at least a first flap pair and a second flap pair, where each of the individual flaps comprising the flap pair has a first and second longitudinal edge on opposite sides of a first and second width ends, the first width end is attached to a control arm with a plurality of ramps, the control arm is located above the heat source and below a cooking surface, wherein the first and second flap pair are arranged so that a channel exists between the first flap pair and the second flap pair when the control arm is in a first position where the flap pairs are elevated between 20 to 60 degrees from the horizontal to form an apex to a second position where the flap pairs are essentially horizontal.
 13. The grill according to claim 12 wherein: the heat source is gas fueled.
 14. The grill according to claim 12 wherein: the flap pairs have a first arched tab on the first width end for engaging the control bar.
 15. The grill of claim 12 further comprising: at least one end flap having a first and second longitudinal edges on opposite sides of a first and second width ends, the first and second width ends are attached to the control arm.
 16. The grill of claim 12 wherein: the bottom wall of the firebox is a removable attached ash pan for catching grease and charcoal ash channeled by the flap pairs away from the heat source.
 17. The grill of claim 12 wherein: the firebox has a bottom wall, a front wall and a back wall that are essentially parallel to each other and extend upward from the bottom wall, and a left side wall and a right side wall that extend upward from the bottom wall, are connected to the front wall and the back wall, and are essentially parallel to each other.
 18. The grill of claim 12 wherein: the flap pairs are vented for letting gasses through.
 19. A method for cooking with charcoal on a gas grill comprising: positioning a plurality of flaps that are rotationally attached inside a firebox in essentially a horizontal position by placing a control bar connected to the flap pairs in a first position; arranging charcoal briquettes on top of the plurality of flaps in a configuration suitable for igniting; engaging a heat source located in the bottom of the firebox underneath the flaps; permitting the heat source to ignite the charcoal briquettes through the spaces between the flaps.
 20. A method for cooking with charcoal on a gas grill according to claim 19 further comprising: disengaging the heat source once the charcoal briquettes are ignited.
 21. A method for cooking with charcoal on a gas grill according to claim 19 further comprising: spreading the ignited charcoal briquettes evenly over the flaps in preparation for cooking.
 22. A method for cooking with charcoal on a gas grill according to claim 19 further comprising: applying a cooking surface for cooking food above the flaps.
 23. A method for cooking with charcoal on a gas grill according to claim 19 further comprising: burning the charcoal to ash; displacing the charcoal ash by positioning the control arm connected to the flaps in a second position thus moving the flaps into an apex position and thereby permitting the charcoal ash to fall to a drip pan in the bottom of the firebox; and removing the charcoal ash collected in the drip pan by withdrawing the drip pan and discarding the ash.
 24. The method according to claim 19 wherein: the permitting the heat source to ignite the charcoal briquettes step takes between 5 to 10 minutes.
 25. The method according to claim 19 wherein: the heat source is gas fueled. 